engine NISSAN PICK-UP 2001 Repair Manual

Maintenance Schedule for Diesel Engines
(Annual Mileage > 30,000 km/year)
YD25DDTi ENGINE
Abbreviations: R = Replace I = Inspect: Correct or replace if necessary, C = Clean D = Check filter and drain water
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Refer-
ence
pages Perform on a kilometer basis only.km x 1,000
(miles x 1,000)20
(12)40
(24)60
(36)80
(48)100
(60)120
(72)
Engine compartment and under vehicle
Engine oil (For 2WD models or
4WD appearance 2WD models,
use API CF-4 oil)HRRRRRR3012
Engine oil (For 4WD models, use
API CF-4 oil)HReplace every 10,000 km (6,000 miles) 3012
Engine oil filter (Use Eco filter or
equivalent)HSee NOTE (1)RRRRRR3013
Drive beltsIIIIII3011
Cooling systemIIIIII3016
Engine anti-freeze coolant (Use
genuine NISSAN Anti-Freeze Cool-
ant (L250) or equivalent)See NOTE (2) I R 3014
Air cleaner filter (Viscous paper
type)HR R 3019
Air cleaner filter (Dry paper type)HCRCRCR3019
Cyclone pre-air cleanerHIIIIII3019
Intake & exhaust valve clearance See NOTE (3)*1
Fuel linesI I 3019
Injection nozzles See NOTE (4)*2
Fuel filterHDDRDDR3018
NOTE: (1) Oil filter element assembly (Part No. 15208 AD200) and O-ring seal (Part No. 15226 AD200) are replacement parts.
(2) First replace at 100,000 km (60,000 miles), then every 60,000 km (36,000 miles). After first replacement, perform
ªIº (checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement inter-
val.
(3) If valve noise increases, check valve clearance.
(4) If engine power decreases, black exhaust smoke is emitted or engine noise increases, check injection nozzles and
if necessary, replace injection nozzle assembly.
HMaintenance items with ªHº should be performed more frequently according to ªMaintenance Under Severe Driv-
ing Conditionsº.
*1: ªValve Clearance Inspection and Adjustmentº in EM section
*2: ªInjection Tube and Injection Nozzleº in EC section
PERIODIC MAINTENANCE
MA-3006

Maintenance Under Severe Driving
Conditions (Annual Driving Distance > 30,000
km/year)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be
performed on the following items as shown in the table.
A Ð Driving in dusty conditions
B Ð Repeatedly driving short distances
C Ð Towing a trailer or caravan
D Ð Extensive idling
E Ð Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F Ð Repeated driving at high speeds and/or at high engine load
Driving condition Maintenance itemMaintenance
operationMaintenance intervalReference
pages
ABCD ..
Engine oil
Petrol models (KA engine) ReplaceEvery 7,500 km
(4,500 miles)Ð
Diesel models
(YD engine)2WD models or
4WD appearance 2WD modelsReplaceEvery 10,000 km
(6,000 miles)3012
4WD models ReplaceEvery 5,000 km
(3,000 miles)3012
.....FDiesel models
(YD engine)All 2WD and 4WD versionsCheck oil level,
correct if neces-
saryEvery 5,000 km
(3,000 miles)Ð
ABCD ..Engine oil filter
Petrol models (KA engine) ReplaceEvery 7,500 km
(4,500 miles)Ð
Diesel models (YD engine) ReplaceEvery 10,000 km
(6,000 miles)3013
A.....Air cleaner filter (Viscous paper type)
Petrol models (KA engine) ReplaceEvery 30,000 km
(18,000 miles)3010
Diesel models (YD engine) ReplaceEvery 30,000 km
(18,000 miles)3019
A.....Air cleaner filter (Dry paper type)
Diesel models (YD engine)CleanEvery 10,000 km
(6,000 miles)3019
ReplaceEvery 20,000 km
(12,000 miles)3019
A.....Cyclone pre-air cleaner
Diesel models (YD engine) Inspect More frequently 3019
A.....Positive crankcase ventilation (PCV) filter
Petrol models (KA engine) ReplaceEvery 30,000 km
(18,000 miles)3010
A...E.Fuel filter
Petrol models (KA engine) ReplaceEvery 45,000 km
(27,000 miles)Ð
Diesel modelsReplaceEvery 30,000 km
(18,000 miles)3018
Check & drain
waterEvery 10,000 km
(6,000 miles)3018
PERIODIC MAINTENANCE
MA-3007

Fluids and Lubricants
Capacity (Approximate)
Recommended Fluids/Lubricants
LiterImp
measure
Engine oil (Refill)
With oil filter
Gasoline engine: API SG, SH or SJ*1
ILSAC grade GF-I or GF-II*1
Diesel engine: API CD, CE, CF, CF-4 for TD engine*1,
*5
ACEA B3-96, 98 or ACEA B3/E3 96, 98 for TD engine*4
API CF-4 for YD engine*1, *5
ACEA 98-B1 for YD engine KA24DE2WD 3.6
4WD 4.13-1/8 qt
3-5/8 qt
YD25DDTi2WD 5.6 *7
4WD 4.34-7/8 qt *7
3-3/4 qt
Without oil filter
KA24DE2WD 3.3
4WD 3.82-7/8 qt
3-3/8 qt
YD25DDTi2WD 5.3 *7
4WD 4.04-5/8 qt *7
3-1/2 qt
Cooling system (With reservoir)
KA24DE 6.9 6-1/8 qt
Genuine Nissan Anti-freeze Coolant (L250)
or equiva-
lent*6
YD25DDTi 8.6 7-5/8 qt
Manual transmission
gear oilFS5R30A2WD 2.8
4WD 5.14-7/8 pt
9pt
API GL-4, Viscosity SAE 75W-85 only
FS5W71C2WD 2.0
4WD 4.93-1/2 pt
8-5/8 pt
Transfer fluid TX10A 2.2 2 qt Genuine Nissan ATF or equivalent*2 or API GL-4*1
Differential gear oil
Front R180A 1.3 2-1/4 pt
Standard differential gear: API GL-5*1
Limited-slip differential (LSD) gear: Gear Oil Hypoid
LSD or equivalent*3 Rear C200 1.3 2-1/4 pt
Power steering fluid Ð Ð Type DEXRON
TMIII or equivalent
Brake and clutch fluid Ð Ð DOT 3 or DOT 4 (U.S. FMVSS No. 116)
Propeller shaft grease Ð Ð NLGI No. 2 (Lithium soap base)
Multi-purpose grease Ð Ð NLGI No. 2 (Lithium soap base)
*1: For further details, see ªSAE Viscosity Numberº.
*2: Contact a NISSAN dealership for more information regarding suitable fluid, including recommended brand(s) of DEXRONTMIII/MERCONTMAuto-
matic Transmission Fluid.
*3: API GL-5, SAE 140 and 10% volume of LSD Friction Modifier (Part No.: 38469-C6000) is an equivalent.
*4: If ACEA B3-96, 98 oils are not available, API CD, CE, CF, CF-4 oil may be used. However, ACEA oils are strongly recommended if at all possible.
*5: Never use CG-4 grade oil.
*6: Use Nissan Genuine Anti-freeze Coolant (L250), or equivalent in its quality,
in order to avoid possible aluminum corrosion within the engine cool-
ing system caused by the use of non-genuine engine coolant.
Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be covered by
the warranty even if such incidents occurred during the warranty period.
*7: Including 4WD appearance 2WD models.
RECOMMENDED FLUIDS AND LUBRICANTS
MA-3008

Changing Air Cleaner Filter
VISCOUS PAPER TYPE
The viscous paper type filter does not need cleaning
between renewals.
Changing Positive Crankcase Ventilation
(PCV) Filter
Remove air cleaner cover and take out PCV filter located inside
air cleaner cover. Then install new PCV filter.
SMA243C
SMA167D
ENGINE MAINTENANCEKA24DE
MA-3010

Checking Tightening Torque
Checking should be performed while engine is cold.
MANIFOLD BOLTS AND NUTS
Intake
: 19.7 - 23.5 Nzm (2.0 - 2.3 kg-m, 15 - 17 ft-lb)
Exhaust
: 28.5 - 33.3 Nzm (2.9 - 3.3 kg-m, 21 - 24 ft-lb)
EXHAUST TUBE NUTS
: 41 - 48.0 Nzm (4.1 - 4.9 kg-m, 30 - 35 ft-lb)
Checking Drive Belts
INSPECTION
+Before inspecting the engine, make sure the engine has
cooled down; wait approximately 30 minutes after the engine
has been stopped.
+Visually inspect all belts for wear, damage, or cracks on
contacting surfaces and edge areas.
+When measuring deflection, apply 98 N (10 kg, 22 lb) at the
.marked point.
+When checking belt deflection immediately after
installation, first adjust it to the specified value. Then,
after turning the crankshaft two turns or more, re-adjust
to the specified value to avoid variation in deflection
between pulleys.
+Tighten idler pulley lock nut and measure deflection
without looseness.
Drive Belt Deflection:
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied*
mm (in)
New AdjustedLimit for re-tight-
ening
Air conditioner
compressor belt7-8
(0.28 - 0.31)9.5 - 10.5
(0.374 - 0.413)12.0 (0.472)
Alternator & water
pump belt6.5 - 7.5
(0.256 - 0.295)8 - 9.5
(0.315 - 0.413)12.5 (0.492)
Power steering
pump belt6.5 - 7.5
(0.256 - 0.295)8-10
(0.31 - 0.39)11.5 (0.453)
*: When engine is cold.
ADJUSTMENT
+Adjust belts with the parts shown below.
Applied belt Belt tightening method for adjustment
Air conditioner compressor belt Adjusting bolt on idler pulley
Alternator water pump belt Adjusting bolt on alternator
Power steering pump belt Adjusting bolt on idler pulley
CAUTION:
+When a new belt is installed as a replacement, adjust it
to the value specified under ªNewº accommodations
because of insufficient adaptability with pulley grooves.
+If the belt deflection of the current belt is out of the
ªLimit for re-tighteningº, adjust to the ªAdjusted valueº.
SMA168D
ENGINE MAINTENANCEYD25DDTi
MA-3011

+When checking belt deflection immediately after
installation, first adjust it to the specified value. Then,
after turning crankshaft two turns or more, re-adjust it to
the specified value to avoid variation in deflection
between pulleys.
+Make sure the belts are fully fitted into the pulley
grooves during installation.
+Handle with care to avoid smearing the belts with oil or
cooling water etc.
+Do not twist or bend the belts with strong force.
Air conditioner compressor belt and power steering
pump belt
1. Loosen idler pulley lock nut (A).
2. Turn adjusting bolt (B) to adjust.
+Refer to MA-3011, ªInspectionº for adjustment values.
3. Tighten lock nut (A).
Nut A:
: 30.4 - 39.2 Nzm (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
Alternator & water pump belt
1. Loosen adjuster lock nut (C).
2. Loosen alternator fixing nut (D) (Rear).
3. Turn adjusting bolt (E) to adjust.
+Refer to MA-3011, ªInspectionº for adjustment values.
4. Tighten nut (C) and nut (D) in this order.
Nut C:
: 19.6 - 23.4 Nzm (2.0 - 2.3 kg-m, 15 - 17 ft-lb)
Bolt D:
: 45.1 - 59.7 Nzm (4.6 - 6.0 kg-m, 34 - 44 ft-lb)
Changing Engine Oil
WARNING:
+Be careful not to burn yourself, as the engine oil is hot.
+Prolonged and repeated contact with used engine oil
may cause skin cancer; try to avoid direct skin contact
with used oil. If skin contact is made, wash thoroughly
with soap or hand cleaner as soon as possible.
1. Put vehicle horizontally.
2. Warm up engine, and check for oil leakage from engine com-
ponents.
3. Stop engine and wait more than 10 minutes.
4. Remove drain plug and oil filler cap.
5. Drain oil and refill with new engine oil.
Oil Specification and Viscosity:
+API CD, CE, CF or CF-4 (Except for Europe)
+API CF-4 or ACEA 98-B1 (For Europe)
Refer to MA-3008, ªRECOMMENDED FLUIDS AND LUBRI
CANTSº.
SMA169D
SMA157D
ENGINE MAINTENANCEYD25DDTi
Checking Drive Belts (Cont'd)
MA-3012

Refill oil capacity (Approximately):
Unit:!(Imp qt)
Item 2WD * 4WD
Drain and refillWithout oil filter
change5.3 (4-5/8) 4.0 (4-1/4)
With oil filter
change5.6 (4-7/8) 4.3 (4-1/2)
Dry engine (engine overhaul) 6.3 (5-1/2) 5.0 (4-3/4)
* : Including 4WD appearance 2WD models.
CAUTION:
+Be sure to clean drain plug and install with new washer.
Drain plug:
:29-39Nzm (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
+The refill capacity depends on the oil temperature and
drain time. Use these specifications for reference only.
Always use the dipstick to determine when the proper
amount of oil is in the engine.
6. Check oil level as follows.
a. Start engine and check area around drain plug and oil filter
for oil leakage.
b. Run engine for a few minutes, then turn it off. After more than
10 minutes, check oil level.
Changing Oil Filter
SMA158D
SMA155D
SMA159D
ENGINE MAINTENANCEYD25DDTi
Changing Engine Oil (Cont'd)
MA-3013

REMOVAL
1. Place a pan to catch the oil under the lower part of drain hose
outlet before removing filter body.
2. Using a hexagonal socket wrench [plane-to-plane width: 24
mm (0.94 in)], loosen the filter body approximately four turns.
3. Remove the filter body, then remove the oil filter element.
4. Remove the O-ring from the filter body.
+Push the O-ring in one direction, lift the slack part using
fingers, and remove the O-ring from the filter body.
CAUTION:
Do not use wires or flat-bladed screwdrivers etc. as they
may cause damage to the filter body.
INSTALLATION
1. Completely remove all foreign objects adhering to the inside
of the filter body or O-ring mounting area (filter body side and
bracket side).
2. Install the oil filter element and O-ring to the filter body.
+Push the oil filter element into the filter body completely.
3. Install the filter body to the oil filter bracket.
:20-25Nzm (2.0 - 2.6 kg-m, 15 - 18 ft-lb)
4. After warming up the engine, check for engine oil leakage
and oil level.
CAUTION:
Completely wipe clean any engine oil remaining on the fil-
ter body or vehicle.
Changing Engine Coolant
To avoid the danger of being scalded, never change the
coolant when the engine is hot.
Ð DRAINING ENGINE COOLANT Ð
1. Set air conditioning system as follows to prevent coolant from
remaining in the system.
a. Turn ignition switch ON and set temperature controller to
maximum hot position.
b. Wait 10 seconds before turning ignition switch OFF.
2. Open radiator drain plug at the bottom of radiator and
remove radiator cap to drain coolant.
SMA160D
JLC292B OK
SMA161D
ENGINE MAINTENANCEYD25DDTi
Changing Oil Filter (Cont'd)
MA-3014

3. Remove reservoir tank, drain coolant, then clean reservoir
tank.
+Be careful not to allow coolant to contact drive belts.
4. Remove drain plug of cylinder block.
5. Check drained coolant for contaminants such as rust, corro-
sion or discoloration. If contaminated flush engine cooling
system, refer to MA-3016, ªFLUSHING COOLING SYS-
TEMº.
Ð REFILLING ENGINE COOLANT Ð
1. Install reservoir tank, radiator drain plug and cylinder block
drain plug.
+Apply sealant to the thread of cylinder block drain plugs.
:8-11Nzm (0.8 - 1.2 kg-m, 70 - 104 in-lb)
2. Fill radiator with coolant to the filler neck of the radiator cap
at a rate of 2!(1-3/4 Imp qt)/min or lower.
+Use genuine Nissan Anti-freeze Coolant or equivalent
mixed with water (distilled or demineralized).
Refer to MA-3008, ªRECOMMENDED FLUIDS AND LUBRI-
CANTSº.
CAUTION:
If the filling rate is too fast, this could lead to air being mixed
in the coolant. Be sure to fill the coolant slowly according
to the rate indicated above.
Engine coolant capacity (With reservoir tank):
8.6!(7-5/8 Imp qt)
Reservoir tank capacity:
0.7!(5/8 Imp qt)
3. Fill reservoir tank to the MAX level.
4. Warm up engine to normal operating temperature without
radiator cap installed.
+If coolant overflows radiator filler hole, install radiator
cap.
5. Run engine at 3,000 rpm for 10 seconds and return to idle
speed with radiator cap installed.
+Repeat two or three times.
Watch coolant temperature gauge so as not to overheat the
engine.
6. Stop engine and cool it down.
+Cool down using a fan to reduce the time.
+If necessary, refill radiator up to filler neck with coolant.
7. Refill reservoir tank to MAX level line with coolant.
8. Repeat steps 4 through 7 two or more times with radiator cap
installed until coolant level no longer drops.
9. Check cooling system for leaks with engine running.
SMA162D
SMA182B Radiator
SMA412B
ENGINE MAINTENANCEYD25DDTi
Changing Engine Coolant (Cont'd)
MA-3015

10. Warm up engine, and check for sound of coolant flow while
running engine from idle up to 3,000 rpm with heater tem-
perature controller set at several positions between COOL
and HOT.
+Sound may be noticeable at heater water cock.
11. If sound is heard, bleed air from cooling system by repeat-
ing steps 4 through 7 until coolant level no longer drops
+Clean excess coolant from engine.
Ð FLUSHING COOLING SYSTEM Ð
1. Fill radiator and reservoir tank with water and reinstall radia-
tor cap.
2. Run engine and warm it up to normal operating temperature.
3. Rev engine two or three times under no-load.
4. Stop engine and wait until it cools down.
5. Drain water.
6. Repeat steps 1 through 5 until clear water begins to drain
from radiator.
Checking Cooling System
WARNING:
Never remove the radiator cap when the engine is hot; seri-
ous burns could be caused by high pressure fluid escaping
from the radiator.
Wrap a thick cloth around the cap and carefully remove it by
turning it a quarter turn to allow built-up pressure to escape
and then turn the cap all the way off.
CHECKING COOLING SYSTEM HOSES AND CLAMPS
Check hoses and clamps for improper attachment, leaks, cracks,
damage, loose connections, chafing and deterioration.
CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator
as follows.
+Be careful not to bend or damage the radiator fins.
+When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, radiator shroud and
horns. Then tape the harness and connectors to prevent
water from entering.
1. Apply water by hose to the back side of the radiator core
vertically downward.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radia-
tor.
4. Blow air into the back side of radiator core vertically down-
ward.
+Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm
2,
71 psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out.
ENGINE MAINTENANCEYD25DDTi
Changing Engine Coolant (Cont'd)
MA-3016